Method of manufacture of electrically heated devices and electricresistance heating elements therefor



APU] 26, 1949- A. E. REIMERs 2,468,409

METHOD 0F MANUFACTURE oF ELECTRICALLY HEATED DEVICES AND ELECTRIC-RESIsTANcE-HEATING ELEMENTS THEREFOR Original Filed Sept. 18, 1940 2 Sheets-Sheet l Pgfl I .P3-t E IN V EN TOR.

A L FR ED E. Femm-e5 BY W April 26, 1949- A. E. REIM s 2,468,409

METHOD OF MANUFACT E ELE ICALLY H A ED DEVICES EL RIC-RESI A -HEATING ELEME THEREF Original Filed t. 1940 2 She s-Sheet 2 L113 @5w C21' L19 (21 154/ 1g IN VEN TOR. ALFRED i PE1 MERS Pa-.tented Apr. 26, 1949 METHOD OF MANUFACTURE OF ELECTRI- CALLY HEATED DEVICES AND ELECTRIC- RESISTANCE HEATING ELEMENTS THERE- FOR Alfred E. Reimcrs, Harrington Park, N. J.

Original application September 18, 1940, Serial No. 357,264, now Patent No. 2,403,022, dated July 2, 1946. Divided and this application June 18, 194,6, Serial No. 677,462

9 Claims.

This invention relates to improvements in methods of manufacture of electrically-heated devices having cast-in electrical-resistance elements, and particularly to methods of manufacture of such devices as sadirons, hot plates, cooking utensils and other types of electrical heating apparatus employing flat electric-resistance heating elements, and constitutes a division of my early application Serial No. 357,264, filed September 18, 1940, entitled Electrically heated devices, electric-resistance heating elements therefor .and methods of manufacture thereof, and which has, during pendency of this application, matured into Patent No. 2,403,022, issued July 2,1946.

Embedding electric heating resistors has long been found a reliable means of transmitting the developed heat to the working surfaces of the devices they are required to heat. Certain factors, however, limit the effectiveness of such embedding and embedded resistors. For example, where emcient design and moderate to heavy duty is required, the known electrical-insulating and heat-conducting materials are restricted to finely-divided or granular materials that are hard or refractory, friable and uncohesive though compactable, such as electrically-fused alumina, magnesium oxide, and zirconia. These materials possess relatively high heat conductivity and high electrical insulation at elevated temperatures.

Bonding agents such as selected clays were heretofore used to integrate the granular mass when it was used in some plastic condition about the heat producing coil. This method requires the firing of the material to mature or vitrify the bond. Such material with a clay bonding agent was in some cases plastered in grooves in an asbestos or porcelain core-holder. Since the presence of the bond itself limits the temperature at which the embedding material may operate, and as a compacting of such material increases its efciency, heating-element constructions were used in which the material was compacted and no bond was employed, and to this end, such coil-embedding materials were compacted within reinforcing metal tubes and other jackets or containers. This process is expensive as it involves the forming of the costly metal tube or jacket to adapt it to the area and the surfaces of application.

Electrically-heated devices of the cast-in type hereinabove specified have also heretofore been manufactured by casting into the heated device an electric-resistance heating-element in which the aforesaid embedding material was thus reinforced by a metallic tubular member and it has also been proposed to employ cast-in heating elements in which a pastlc embedding composition was molded and so set into a grooved reinforcing core-member of heat-insulating materials such as Portland cement, asbestos, soapstone, talc, quartz, etc, that only a minor part of the surface of the embedding material was exposed or in direct contact with the cast metal. In the latter case, the resultant heating element, because the reinforcing core was unduly thick and clumsy and the major portion of the surface of the coil-embedding material is, in the finished article, separated and insulated from the casting-in metal, thus preventing maximum heat transfer and distribution between the embedding material and the cast-metal and in the former case, the reinforcing tube separates the embedding material from the cast-metal and two bonds are required, one being a cold bond between the inner surface of the metal tube and the embedding material and the other being a metal to metal bond between the outer surface of the tube and the cast metal of the device or article. Also when a sheating-tube, filled with finelydivided refractory or-friable material, is employed in the manufacture of a flat heater device or article, the tube usually must be bent into suitable shape to t the mold in which it is to be cast; and to enable its use with light sections of casting metal, such bending or forming must be very accurate to provide definite and uniform location of the element within the device or article mold. Accurate and uniform shaping of such pieces is very diilicult and in practice, this form of resistance-element is irregular in the cast pieces causing unequal heat-distribution and leaving exposed tube sections, which readily overheat and produce burn-outs. In all such cast-in heated devices or units having tubular metallic-sheathed elements, the initial thickness of the metal sheathing tube also necessarily adds to the thickness of metal between the resistance coils and the heat applying surface.

Such elements having external or core-reinforcements, furthermore, do not lend themselves to the provision therein of closely-related tieforming holes that when the element is cast-in produce heat-distributing ties of cast-metal that assist in providing a unitary electrically-heated device in which all parts of the storing metal and the heat-applying surface will be uniformly and equally heated with a minimum expenditure of heating energy. Also prior art methods of makmortar-set mass of friable, granular d ing such articles and particularly for making relatively flat articles, required a relatively large number of essential parts and a rather involved number of operations to produce the electricallyheated device per se.

'Heretofora also. embedded electrical-resistance heating-elements for sa-dirons and the like that were adapted to be renewed when burned out were made without refractory frames or cores and without metallic sheathing members.' The heating coils in such elements were embedded in. a wet embedding material formed into a mortar, then set, and later reinforced by a hardened outer shell composed of the embedding material and water glass or silicate of sodium. These elements were made and sold under my Patent No. 1,439,121 as independent or separate` articles of manufacture for insertion into a sadiron base. In these elements the embedding material was not compressed, therefore necessarily made relatively thick and were adapted to be fitted closely into and to fill a depression in the body portion or base of a sad-iron. The resulting element was composed of an uncompressed coil-embedding material bonded by a suitable luxing or bonding agent, such as clay, encased in a hardcned shell produced by the application of a coating of silicate of sodium or like material to the outer surface of the mass. This mortar-set mass of embedding material within the hardened shell is relatively fragile and theentire element has little resistance to crushing pressure, while the presence of the bonding agent limits the temperature at which the device may operate. Said wet method of molding was slow and cumbersome, permitted hidden voids and produced a relatively weak structure; also, said method made it dicult to produce elements accurately to the size and smoothness required for a satisfactory element to be'cast into the base of a sad-iron or other electrically-heated device; also made it dlfiicult ot procure accurate and uniform location of the resistors close to the outer surface of the embedding material. These and other factors make it undesirable to use such an element in a cast-in device where the element itself is permanent and not renewable. Furthermore, no one ever contemplated using such elements as a castin heating element and in fact my said uncored and unsheathed element does not possess the necessary properties and qualities to enable it to be successfully used as the heating element in aA cast-in device or article and also for the reasons hereinabove specified does not lend itself to the provision of accurately-positioned yand smooth tie-forming bores or holes extending through the body of the element. f

While compressed embedding material reinforced by tubes has, as aforesaid, been used in cast-in devices or articles, I have heretofore found it to be impractical to cast-in sheathed or jacketed elements of at or similar shape because the flat middle portions in the casting-in process buckle away from the embedding material and leave voids or spaces that prevent emcient heat transfer to the cast metal.

One of the objects of my invention is to provide methods of manufacture of cast-in electrical-resistance heating elements for electric stove heaters, flat irons and the like, that will possess the essential qualities of compactness and fast heating and to this end will avoid such excessive mass and bulk that would of itself prevent rapid heating, and instead provide an element that will possess minimum bulk combined with a maximum area of heat-transfer surface in direct contact with the heat-storing material, such as cast-iron of the device or article to be heated.

Another object of my invention is to produce methods of manufacture of unsheathed and uncored electric-resistance heating-elements formed of resistor coils 'embedded in said highly efficient resistance-coil-embedding material that will provide in the electrical-resistance heating-element the advantages of an extremely light proportion of bonding material, yet having adequate strength; the accurate location of the element and its coil to serve, as required, the body portions of the article tobe heated, plus an intimate bond between the embedded unit and the article itself, and to accomplish this with lowest cost due to few parts'and few operations.

Another object of my invention is to provide methods of manufacture of electric-resistance elements that will, in themselves, with a minimum of bulk, possess sufcient strength, rigidity and resistance to crushing pressure as to permit. Without the use of reinforcing cores or metal sheathing members, a casting directly into an electrically-heated device or article.

Another object of my invention is to provide methods of manufacture of heating elements formed of heating coils and terminals embedded in said refractory and friable electrical-insulating and heat-conducting material so co-related and arranged as to eliminate the necessity for any reinforcing core or metal jacket, sheath or tube and to provide a body surface which will, in the casting operation enable the molten lmetal of the device or article to have an increased contact with the surface of the embedding material without the intervention of any insulating holding core or reinforcing metal sheath member and Without any intervening -or with negligible film or heat-impeding layer, and preferably will provide'a contacting heat-transfer surface between the embedding material and cast metal which will extend substantially all around s aid embedding material.

Another object of my invention is to furnish a method of manufacture of an electrical-resistance element of the type hereinabove described embodying the aforesaid highly eiilcient uncontained, and unsheathed heat-conducting and electrical-insulating material which will definitely provide, in the finished article, for the desired heat distribution and for the accurate positioning of the coils, insulation and terminal pieces.

Another object of my invention is to provide a method of manufacture that will produce such accurate positioning and definite relationship by a series of simple operations which will cause uniformity in the finished product and. will provide an element that will not, to any material degree, crack or crumble in the casting process under the heat and pressure of molten metal but which, on` the contrary, will without any reinforcement, maintain its integrity and uniformityv of shape during the casting operation, and furthermore, will, in the flnished article, provide smooth uniform walls and surfaces that will enable uniform thickness of the walls of metal articles to be produced in casting.

Another object of my invention is to coat a compressed embedding material unit with a coating flux, such as phosphoric acid, water glass or one of a number of substances which will be suitable for the purpose of reinforcing said comama-ica pressed mass of embedding material and that will produce a vitriiied shell with a coefficient of expansion close to that of the embedding material.

Another object of my present invention is to provide methods of manufacture of an element in which the making of the coil-embedding heatconducting and electrical-insulating material accomplished by packing and compressing in suitable dies under high pressure in apress, the finely-divided refractory and otherwise friable electrical-insulating and heat-conducting material and after such compressing further strengthening the element of refractory or friable insulating material by impregnating the element with a fiux of strengthening material so as to produce a body of embedding material encased in a vitriied reinforcing shell of minimum thickness and having a coeilicient of expansion that l will provide a proper bond between the surface of the element and the cast metal walls of the article into which it is cast.

Another object of my invention is to provide methods of manufacture of a resistance element formed of a compressed embedding material that methods of manufacture which eliminate the cold bond between the insulating material and metal sheathing of former units and substitute therefor, an intimate hot autogenous bond between the compressed refractory and friable insulating material and the liquid or molten cast-in metal in which all depressions and/or holes, large and small, in the contacting surface of the unit may be lled with the cast metal of the article.

Another object of my invention is to provide a new method of embedding the resistance coil or coils and compressing the finely-divided insulating material around the same which comprises first providing a suitable die, filling the same initially with insulating material preferably having a suitable temporary bond adapted to be eliminated in the subsequent firing, then compressing, preferably by a high pressure produced with a hydraulic press, the finely-divided material to about half the original thickness and simultaneously pressing into and embedding just below the top surface of the insulating material,

comprises in one of its adaptations the species or preferred form illustrated in the accompanying drawings, in which:

Fig. 1 is a view in plan of a hydraulic press and loading table adapted for use in compressing my bare or unsheathed electric-resistance heating A elements;

Fig. 2 is a view in elevation of the in Fig, 1;

Fig. 3 is a view in side elevation of a form or coil-mounting member for mounting a resistance coil suitable for use in an electrical-resistance heating-element for sadirons;

Fig. 4 is a view in plan from the bottom of the form or mounting member shown in Fig. 3;

Figs. 5 and 6 are plan and side elevation views of one of my bare electrical-resistance heating elements in finished form after the compressing operation;

Fig. 7 is a longitudinal section, partly broken away of the form or coil-mounting member shown in Figs. 3 and 4;

Fig. 8 is a view in cross-section of a die suitable for use in the press shown in Fig. 1 and showing the cavity lled with insulating material and levelled off ready for embedding of a resistor coil and compressing said material;

Fig. 8*l shows a similar view of the die and the press shown V position of the resistor coil, terminals and insulation after an initial pressing operation to embed the resistor coil;

. Fig, 9 is another similar View showing the condition of the insulating material, die and ernbedded resisting element after a second filling and pressing operation;

Fig. 10 is a fragmentary section of a portion of a resistor coil, terminal and electric-insulating and heat-conducting material;

Fig. 11 is a fragmentary view in section similar to Fig. 9 showing a modified form of element having two resistor coils embedded in the embedding material;

Fig. 12 is an elevation of a mold employed by me with the face plate removed;

Fig. 13 is a vertical section on the line |3-I3 of the mold shown ln Fig. l2 and Fig. 14 is a section on the line lil-I4 of Fig. 12, looking in the direction of the arrows.

Referring now to these drawings which illustrate a preferred embodiment of my invention, I rst prepare a iat, bare or unsheathed electric resistance heating-element by completely embeda resistor coil and terminal; then secondarily filling the die above said compressed portion and secondarily compressing the secondary filling with the initial resistor-embedding body to provide a suitable thickness of compressed material surrounding the resistance coil or coils. The compressed unit thus produced will possess sufllcient strength to enable releasing or ejecting from the die and moving the same for drying in a hot air chamber. The element is then further impregnated or coated on its outer surface with a strengthening material and then baked at high temperature whereupon the temporary bond is eliminated, the strengthening material is vitried and the element is ready for the casting-in operation.

With these and other objects in view, the invention comprises the combination of members and arrangement of parts so combined as to co-act and cooperate with each other in the perfomance of the functions and the accomplishment of the results herein contemplated, and

ding a resistor coil in compressed finely-divided electrical-insulating and heat-conducting material, exposing terminals of said coil and providing during the preparation a series of tie holes extending through said flat piece; and I then cast-in said electric-resistance heating-element within a suitable mold to produce the final electrically-heated device such as a sadiron base,

In accordance with my invention I provide element proportions affording compactness combined with eiilciency of design that will be consistent with eiiicient performance. By efficiency of design is meant particularly two factors, l: the proportion of' bulk or mass of heating unit to that of the article to be heated; and 2: the locating closely to the surfaces (or parts to be heated) of the heating element. In this invention these factors are in turn largely dependent on permissible proportions of the heating element. It follows that eflicient and practical design employing fiat embedded elements, may be stated in terms of proportions of the heating element, as follows: When heater element thickness exceeds six per cent of the sum of the two major dimensions, i. e., length and breadth. or' two diameters if round, it becomes impractical for most applications. On the other hand I find that a thickness ratio of from three to four per cent of that sum is entirely practical, effective in most designs, ailords rapid heating and is efdcient in use. l

In accordance with my invention I also provide a heating element in which only a smalll proportion of bonding materials which would normally give a low degree oi strength in the mass is employed and yet strength for handling and to stand the strains of the casting-in process are supplied. To this end, I coat the element after it is pressed an dried, with a flux which is preferably sprayed onto its surface. The element is then dried a second time and then red. In tiring. the ux and surface particles of the embedding mass vitrify, 'forming an extermely thin though strong outer shell having a minimum thickness amounting to about .010 inch.

I rst proceed to manufacture such an electric heat resistance element by the use of the following apparatus and methods:

`To procure compression and embedding oithe resistor coil within the nely-divided electricalinsulating and heat-conducting material, I preferably employ a hydraulic press l of conventional type, having a loading table 2, a press head 3 and a bed plate d '(see Fig. 2). VA. resistance-coil mounting-form 5 which, in Figs. 3 and 4 has the shape of a flat-iron base, is mounted on the head 3 of the press and consists, as shown, of a back or pin carrier plate 6 having a hollow shank member l projecting upwardly therefrom. A stripper plate 8 is loosely coupled with the pin carrier plate by means of the upwardly projecting stem 9 carrying the latch lil which passes through an opening 1' in the ltop of the hollow shank 'l and latches over the top plate l of the shank. These two plates are slightly spaced from each other though resiliently retained in aligned relationship to each other by the spring 1b which abuts at one end against the inner surface of the top plate 1EL and at the other end against the top of the stem 9. The plate carries a series of projecting tapered pins ll which pass through clearance holes I2 in the stripper plate and project from the opposite surface of said stripper plate 8 a sufcient distance to enable the support on such pins of a helically-coiled wire resistance member i3. This wire resista-nce i@ is strung upon the projecting pins to abut the outer surface of the stripper plate and the pins are so arranged in relation to the plates to enable the-secure Stringing and supporting of the helically-coiled resistance wire I3 by the spring tension of the coils and said resistor coil. may be made to assume any suitable shape desired. In the embodiment shown in Figs. 3 and 4, the helically-coiled wire resistance member strung on the pins il is suitable for use as a resistor coil. in an electric-resistance heatingelement adapted to be cast-in within a sad-iron base. Obviously, the pins il are positioned and the resistance coil may be strung thereon to provide a resistor-coil for use in an electric-resistance heating-element adapted to be cast in many different shapes and capable of use in any ilat electric-resistance heating-element for use in hot-plates, cooking utensils and other apparatus.

The mounting member 5 for the helicallycoiled resistance wire is produced, as aforesaid,

(8 beneath the head 3 of the press, the mounting in the embodiment shown being accomplished by passing the shank 1`upwardly through a suitable aperture in the head 3 and locking the same in position by the use of a spring-pressed latch I4 which engages in a notch 'lc formed in a wall of the shank 1; and is adapted to cooperate with a die in the press I to compress a finely-divided electrical-insulating and heat-conducting material and embed the resistance-coil therein. Thus, a ydie i5 is mounted on a bed plate 4 and the plates so combined are placed upon the loading table 2. The die i5 comprises a die-base l5* and a. die i5 and is provided with a cavity i5', the depth of which is shown in cross-section in Fig. 8, the shape of said cavity being in the form of the article to be produced and, as shown, having the shape or form illustrated in Figs. 3 and 4. This cavity I5' is provided with a closelyiltting stripper member I5* at the bottom thereof and is rllled and overflowed with finely-divided vor powdered coil-embedding material which preferably comprises a nely-divided refractory and otherwise friable electrical-insulating and heatconducting material. The excess material is then struck oiI and levelled in any suitable way such as by the scraper plate i8, and the material in said cavity is subjected to a compression pressure under ythe power of the hydraulic press preferably to such an extent that the material M in the cavity I5' of the die I5 will be compressed to approximately three-eighths of its initial thickness. In the compressing operation, by the use of the handle I'l (Fig, 1) the lled die is moved from-the loading table 2 on rails I8 guided by a center guide rail I9 onto the platen 20 of the press. The platen of the press is then raised by the hydraulic power of the press to produce a rst press stroke and the resultant pressure causes the embedding of the resistance coil i3 in the material M, and the compression oi. the material in the die cavity. In this rst stroke or operation, the pressure produced on the plate 8 of the form member 5 first takes up the slack or space between the plates 6 and 8 and compresses the spring 'lb to free the head of the latch ill from the top plate la which allows a at spring ld, mounted in the hollow shank l, to press the latch I0 out of locking engagement with the notch l in said top la of the said shank and to hold in open position the said latch while said press pressure continues. When the first pressure stroke of the press is completed, the press-platen with the die i5, drops away from the form member 5. During this operation the coiled springl lb 4forces the stripper plate away from the pin mounting plate 6 and so presses down upon the partially formed electrical-resistance element as shown in Fig. 8, until the pins are withdrawn from the compressed embedding material surrounding the resistance coil and its terminal members The completion of the first pressure stroke hus leaves the resistance coils embedded in compressed mat`erial in the die cavity.

r completion of the rst press stroke, as aforesaid, the die I5 and bed d are pulled away from the platen to the loading table 2 where "the remaining unlled portion of the die cavity is again lled with embedding material, as shown in Fig. 8a and the excess struck oi' by a. scraper plate. The form member comprising plates 6 and 8 is then removed from the head 3 of the press and a. iinishing plate of a similar shape is placed on top of the material in the filled die by the use of the plates t and 8 and is mounted t5 cavity and die combination including the plates 4 and I5 are placed in position on the press platen and pressure is again applied in the sam'e manner as hereinabove specified. Upon completion of this second stroke of the press, the die is again .withdrawn after last pressing, on to the loading table, where suitable ejecting mechanism, operating through pins 2|, will engage the pins 2i of the combination die I 5 and through a raising of such ejector pins 2l will force upwardly the loose bottom or stripper plate and the finished electric-resistance element will be ejected from the die cavity. The finishing plate may be removed at any suitabletime and this ejection may be accomplished either before or after such removal.

Some element constructions require additional resistors, and in Fig. 11 I have shown a deeper form of die cavity of the type shown in Figs. 8, 8a and 9, adapted for embedding two resistors in my compressed embedding material. This form of my invention is produced by following the practice hereinabove described except that instead of compressing two layers of embedding material for a single resistor, three layers will be successively compressed. Thus, a second resistor i3a will be partially embedded in the surface of the second layer and a third layer of embedding material will be compressed above the same to nish the element. The terminals |33' of the upper coil will, of course, be of less height than of the lower coil and all the terminals of the two resistor coils will be so positioned as shown so as not to conict with each other.

While I have hereinabove referred to resistor coils, it will be understood that I do not wish to limit myself specifically to the use of coils, as ribbon, strip or like resistors may, in accordance with my invention, be similarly inserted and embedded in compressed embedding material.

From the above, it will be seen that I have produced a compressed electric-resistance heating element having resistance coils properly embedded therein and I find that because of the heavy compression obtained by the use of the hydraulic press, the said element will have sumcient strength and rigidity to enable the same to be handled and subsequently to be mounted in a cast metal mold as hereinafter described, but in the preferred embodiment of my invention, I preferably either prepare the material with a suitable binder prior to compressing the same and/or I may, after pressing the same, treat the compression material with a suitable hardening and strengthening material.

In forming electric-resistance heating-elements for fiat electrically heated devices which are adapted for use in the cast-in process hereinafter described, I preferably provide the form with a series of pins 22 which produce holes 23 in the finished electric-resistance element which holes have a tying function as hereinabove specified.

It will also be seen from the above that I provide an accurately die-outlined element with complete embedding, supporting and surrounding of the resistor coil by walls of accurately-measured thickness and that my method produces a uniform covering of the resistor coils with an electrical insulating and heat-conducting material, and also that I provide for the uniform and accurate location of the terminal members, and also provide in the element, accurate positioning of holes or other parts which are used as supporting means when the same is placed in a mold to scribed.

It will be seen also that I have provided an electric-resistance element comprising a member in flat shape, which may be made of relatively thin depth or cross section, whereby the resistance coil may be distributed longitudinally as required or necessary'7 in relation to the fiat surface to be heated and still the said resistance coil may, in the finished article or device, be positioned close to the surface to be heated with a minimum mass of'insulating material and a minimum mass of cast metal between such resistor and the said surface to be heated.

In producing an electrically-heated device such as a fiat iron base, I provide a two-part mold 2l having a back member 24 and a face or front member 24a so arranged and formed as to produce a suitable molding cavity 25 and pouring conduits therefor. I then mount in the molding cavity 25 of such mold, the bare or unsheathed electric resistance element E. It is desirable to mount and maintain said insulating element E in properly aligned position within the mold cavity and to provide mounting means that will align the same and prevent any shifting thereof in said mold cavity during the casting-in operation.

With this end in view, as shown in Figs. 12 and 13, the lower part of one wall of the mold cavity and preferably lower part of the wall in the block member 24', is provided with a pair of supporting apertures 26 into which the terminals I3' at the lower end of the element are adapted to extend, an insulating spacing ring 26 preferably being positioned on each of such terminals to suitably space the surface of the element E from the wall of the mold, and the upper part of the element is properly spaced and retained or supported in position on the same wall of the mold by providing an upper supporting aperture 26, extending into said aperture a screw 21 suitably mounted in the element E and having a spacing washer 21 cooperating therewith to space the upper part of the surface of the element from said wall of the mold. As shown, the screw 21 is secured in one of the upper tie holes 23 and projects outwardly beyond one side surface thereof, and this screw with the two terminals provide a three-point contact with one wall of the mold cavity. In order to prevent any shifting .of the element E in the holes 26 and 26a, I project at the opposite side of the element E a plurality of resilient abutments 30 adapted to contact with the opposite wall of the cavity in the face member 24a. As illustrated, these resilient abutments comprise extension portions of light springs 30 mounted in three tie-holes 23 at three points adjacent to the supporting holes 26, 26a so as to form, upon the closing of the molding, a threepoint abutment or contact with the said opposite wall thereof and to cooperate with the screw 21 and terminals I3' for the purpose of aligning the element upon the closing of the mold and preventing any shifting of such element after the mold is closed and during the subsequent handling and pouring operation. As illustrated, the body portions of three spiral springs 30 are mounted or seated in three holes in the element and each of these springs has an extension terminal portion 30 projecting above the surface of the element on the side thereof opposite to the rigid projecting members 21 and i3'. When the cover 24a of the mold is applied over the cavity, these terminal portions 30' contact with the inner wall or surface of the said member 24* and aeeaeoe thus, in case the element has shifted outwardly in the mold holes 2t, `will press the same back into properly aligned relationship and will hold said element in proper position during the pouring operation. It will be understood that these springs, as well as the screw and spacing washers. will remain in the element and be embedded in the cast metal during the pouring operation. The figures illustrate a dry sand mold of conventional type, but it will be understood that the same arrangement may be used in a green sand mold provided that small dry sand plugsbe made and set in the green sand at the terminals and at the screw or other third point so that the element might be properly supported in the mold cavity.

In the mold embodiment shown, the molten metal is poured through a conduit 28 connected at 28' with the bottom of the mold cavity so that the molten metal enters said mold cavity 25 through the bottom thereof and rises in a pool to completely surround the element and also to enter and ll the series of holes 23 therein. The

molten metal rises, as aforesaid, and any dirt or impurities oating on the top surface of the molten pool and also expanded air or gas is driven out of the cavity through the riser conduit 29 which is connected at its lower end with the mold cavity and at its upper end is free to the atmosphere.

It will be seen, furthermore, that by providing a at piece of material with holes extending through the same from side to side, I am enabled, in the molding operation when the cast metal ows through such holes, to form secure ties between thin, adjacent, fiat walls formed in the cast metal, which thin walls might otherwise be too weak and expand away from the surface of the insulating element when the same is subjected, in operation, to high temperatures.

The shrinkage or contraction of the metal of the article about the element on cooling obviously causes a pressure to be exerted against the Walls or surfaces of the element. This shrinkage pressure tightens the joint between such metal and the surface of the element so that a tightly contacted and shrink-on autogenous joint between the metal and embedding material provides for highly eilicient heat transfer or conduction through such joint.

In casting-in an element such as hereinabove described, I have found that, after the element is mounted in the mold as hereinabove described, it is desirable to apply. the molten metal to the element gradually and while the mold is positioned in upright position supported on one edge. I, therefore, as shown, position and support the mold in upright position on its bottom edge and pour through the channel or conduit 28 and 28 which extends vertically from the top edge to a point below the bottom of the mold cavity and communicates with said bottom of the mold cavity (within which the element is supported) at the bottom thereof so that the poured metal gradually rises in the cavity and surrounds the element therein. I find that this procedure enables the metal to enter all the tie-holes and cavities and to produce the tight joint hereinabove specied.

In certain types of electrically heated devices, and particularly in devices such as sadirons, Where the heat is controlled by a thermostat and consequently a high degree of operating temperature is not required, I have found that. instead of coating or impregnating the compressed element' with a strengthening material or ilux and baking the same at a high temperature, it is possiblev to economize time and to reduce the cost of manufacture by adding to and mixing with the embedding material, prior to the compressing step, a relatively small quantity of a suitable.

frit, or iiux, such as pulverized glass. then compressing the embedding material in the 'manner hereinabove specified to produce an element and thereafter, before the casting-in operation, baking the elements at a relatively low temperature to cause the frit to be vitried and the mass of embedding material to be bonded.

Having described `my invention, I claim:

i. The method of manufacturing electricallyheated devices which consists in compressing in a die, a body of friable, uncohesive electrical-irsulating and heat-conducting embedding material and simultaneously embedding therein a resistor coil, releasing said compressed body from the die to initially produce a. die-formed compressed heating element having the major portion of its surface composed of such friable, uncohesive embedding material, then mounting said element in a mold cavity having the shape of the iinished article, and pouring metal into the mold to cast-in said element and contact directly with said embedding material, and releasing said cast-metal device from the mold.

2. The. method of manufacturing electricallyheated devices which consists in compressing in a die, a body of friable, uncohesive electricalinsulating and heat-conducting embedding material and simultaneously embedding therein a resistor coil, releasing said compressed body from the die to initially produce a die-formed compressed heating element having the maior portion of its surface composed of such friable, uncohesive embedding material, applying to the said body a ilux, vitrifying said flux by application to said element of heat, then mounting said element in a mold having the shape of the nished article, and pouring metal into the mold to cast-in said element and contact directly with said embededing material, and releasing said cast-metal device from the mold.

3. 'I'he method of manufacturing electricallyheated devices which consists in compressing in a die, a body of friable, uncohesive electrical-insulating and heat-conducting embedding material and simultaneously embeddingtherein a resistor coil, releasing said compressed body from the die to initially produce a die-formed compressed heating element having the major portion of its surface composed of such friable, uncohesive embedding material, applying to the surface layer of said body a thin coat of a flux, vitrifying said surface layer by application of heat, then mounting said element in a mold having the shape of the nished article, and pouring metal into the mold to cast-in said element and contact directly with said embedding material, and releasing said cast-metal device from the mold.

4. The method of manufacturing electricallyheated devices which consists in packing and compressing in a suitable die under high pressure in a press, a body of nely-divided embedding material of friable character, releasing said comescasos embedding material to produce a body of embedding material encased in a vitried reinforcing shell of minimum thickness and then pouring cast metal and producing a proper bond between the surface of the element and the cast metal walls of the article into which it is cast.

5. The method of manufacturing electricallyheated devices which consists in compressing in a die, a body of riabie, uncohesive electrical-insulating and heat-conducting embedding material and simultaneously embedding therein a resistor coil to initially produce a die-formed compressed heating element having the major portion of its surface composed of such embedding material, releasing said compressed heating element from the die, then mounting said element in a mold cavity having the shape of the iinished article, supporting said mold to cause the element Within the mold cavity to be supported therein and to extend in a substantially vertical plane, pouring metal into said mold cavity through an edge thereoi` into direct Contact with said element, and subsequently releasing said cast-metal device from the mold.

6. The method of manufacturing electricallyheated devices which consists in compressing in a die, a body of friable, uncohesive electrical-insulating and heat-conducting embedding material andsiinultaneously embedding therein a resistor coil to initially produce a die-formed compressed heating element having the major portion of its surface composed oi such embedding material, reieasing said compressed heating element from the die, providing said element with rigid projections at one side and resilient projections at the opposite side, providing a two-part mold having a molding cavity oi the shape of the device to be produced, forming element-supporting holes in one wall of the said mold cavity in one of said two mold-parts, projecting said rigid mounting porjections into such holes, closing the other part ci said mold against said resilient projections, supporting the mold to entend the cavity in a substantially vertical plane, pouring metal into said mold cavity through an edge thereof into direct contact with said element, and subsequently releasing said cast-metal device from the mold.

7. The method oi manufacturing electrical resistance heating elements for electrically heated devices which consists in supplying to a die-cavity a mass of nicely-divided refractory friable, uncohesive electrical-insulating and heat-conducting embedding material, embedding therein a resistor coil, compressing under heavy pressure in said die-cavity said mass to approximately threeeighths of its initial thickness to produce a dieiormed compressed body, releasing said compressed body from said die-cavity, thereafter applying to said compressed body a vltriable flux, and applying heat to said body to vitriy said flux 'w iurther strengthen said compressed body and ld produce an electrical-resistance heating element capable of withstanding pressure ci casting metal about the same.

S. 'Ihe method of manufacturing electrical resistance heating elements for electrically heated devices which consists in supplying to a die-cavity a mass of iinely-divided refractory and friable, uncohesive electrical-insulating and heat-conducting embedding material, embedding therein a resistor coil, compressing under heavy pressure in said die-cavity said mass to approximately three-eighths ci its initial thickness to produce a de-formed compressed body, simultaneously forming in said body during said compressing operation tie-holes passing through said compressed body to the opposite surfaces thereof, releasing said compressed body from said die-cavity, thereafter applying to said compressed body a vitrinable flux, and applying heat to said body to vitriy said nur to further strengthen said compressed body and produce an electrical-resistance heating element capable ci withstanding pressure of casting metal about the same.

9. The method oi manufacturing electrical resistance heating elements for electrically heated devices which consists in supplying to a die-cavity a mass of @holy-divided refractory and friable, uncohesive electrical-insulating and heat-conducting embedding material, embedding therein a resistor coil, compressing under heavy pressure in said die-cavity said mass to approximately three-eighths or" its initial thickness to produce a die-formed compressed body, simultaneously forming in said body during said compressing operation tie-holes passing through said compressed body to the opposite surfaces thereof, releasing said compressed body from said die-cavity, thereafter applying to said compressed body a vitrinable nux, and applying heat to said body to vitrify said flux to further strengthen said compressed body and produce an electrical-resistance heating element capable o withstanding pressure of casting metal about the same, mounting said element in a mold having the shape or the ilnished article and casting metal in a shell around said compressed body and iilling said tie-holes to provide integral tie portions of said cast metal connecting opposite portions of the shell of cast metal.

"i :rf E. RElMERS.

REFEREINQES CITED The following references are of record in the ille oi this patent:

UNTED STATES PATENTS Number Name Date 522,718 Leonard July l0, 1394i 877,843 Hoskin Jan. 28, i908 1,312,657 Wiegand Aug. l2, i919 l,398,il0 l/Viegand Nov. 29, i921 

